Celebrate National Puzzle Month! Make A Block Puzzle
16th January 2010 by Karen Bastille 1 CommentSince the blocks of wood that make up this puzzle are all the same size and shape, this puzzle is easy to cut out. But beware—once the painted pieces have been jumbled, they are very difficult to put together in proper order, even if you follow the winding paths formed by the graphic clues throughout the design.
Materials
The block puzzle consists of thirty-five pieces of clear pine, each measuring 3/4 by 1& 5/8 by 3 & 1/4 inches. To make them, you will need 10 feet of l-by-2-inch clear pine, cut into 3 & 1/4-inch-long pieces. Most lumberyards will do the cutting for a slight additional charge. However, to ensure accurate measuring, you may want to cut the lumber yourself. Be sure to measure and mark the wood carefully, using a square and allowing for the width of the saw cuts. In addition to the lumber, you will need:
medium- and fine-grade sandpaper;
a piece of 11 & 3/8 -by- 16 & 1/4 -inch paper;
ruler;
11 & 3/8 by-16 & 1/4-inch carbon paper;
and masking tape.
To decorate the blocks, you will need:
a small can of liquid gesso to seal the wood and prepare it for painting;
acrylic paint in four contrasting colors;
medium and small fine-pointed paintbrushes;
and a spray can of clear acrylic sealer.
Making the Puzzle
Smooth the surfaces and edges of each wood block with sandpaper, progressing from medium- to fine-grade. Be careful not to round the edges as you sand, or they will not butt properly when the puzzle is assembled. When the sanding is done, assemble the blocks into the puzzle shape to make sure they have been cut to the proper size. Follow the heavy lines in the pattern below, fitting the pieces together to form an 11 & 3/8-by-l6 & 1/4-inch rectangle. Wipe off the sanding dust, and cover the work surface beneath the blocks with sheets of newspaper to protect it. Apply a coat of gesso to the blocks, painting across the grain of the wood. Cover all six sides of each block, letting each side dry before going on to the next. Then give each block a second coat of gesso, painting with the grain. Let the gesso dry thoroughly.
While the blocks are drying, enlarge the pattern below for painting the puzzle (click on image for full size)

Enlarge the design for the block puzzle by drawing a 1/4-inch grid on a sheet of 13-by-9-inch paper. Transfer the design to the paper, one square at a time. The light lines outline how the puzzle pieces are painted; the heavy lines indicate the separate blocks.
When the blocks are dry, assemble them into the 11& 3/8 -by-16 & 1/4-inch rectangle, again referring to the heavy lines in the diagram above. Wrap tape around the perimeter of the puzzle so the pieces will not shift. Place a piece of carbon paper, carbon face down, on the assembled puzzle and place the pattern, face up, over the carbon paper. With edges matched, tape the pattern and carbon paper in place. Using a sharp pointed pencil, go over the pattern outlines, transferring them to the gessoed surface. If you use a colored pencil to do this, the color will help you keep track of which lines you have transferred. When the pattern has been completely transferred, remove the pattern and unwrap the tape.
Using the color photograph as a guide, paint in the design. Use the medium-size brush for the large areas and the small brush for details. Let each area dry before painting any areas adjacent to it. When the top surface has been completely painted, paint the remaining five surfaces of each block in one color, again letting each surface dry before going on to the next. Finally, apply several coats of the acrylic spray, letting it dry between coats.

















